Body protective device

ABSTRACT

A body protective device for protection of the shin, calf and Achilles regions from impact injuries, especially relating to sports activities, is provided by a composite protector having a fabric outer garment and protective elements, in particular soft elements and semi-rigid and rigid elements, that are selectively provided in predetermined locations within the outer garment for protecting the shin, calf and other proximal body parts from injuries related to impact during sports or athletic activities.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This nonprovisional utility patent application claims the benefit of one or more prior filed copending nonprovisional applications; a reference to each such prior application is identified as the relationship of the applications and application number (series code/serial number): The present application is a Continuation-In-Part of application Ser. No. 10/095,234, which is incorporated herein by reference in its/their entirety.

BACKGROUND OF THE INVENTION

[0002] (1) Field of the Invention

[0003] The present invention relates generally to protective body wear and, more particularly, to a body protective device for protection from impact-based injuries, especially relating to sports and playground activities.

[0004] (2) Description of the Prior Art

[0005] Typically, it is known to provide protective equipment for players in sports activities, especially where the sport involved high impact or the risk of injury from projectiles or bodily contact. However, prior art protective devices to prevent injury to the calf region are not known.

[0006] Prior art protective equipment commonly employs a hard shell that is strapped to the body, e.g., soccer shin guards, helmets, and the like, or a soft, padded covering that is worn as a garment over clothing, e.g., baseball catcher's padded vests, knee and elbow pads for volleyball and basketball, and the like. However, the protective equipment of prior art does not provide adequate protection to the calf and Achilles region from strikes by cleated shoes or skates.

[0007] Data from the US Consumer Product Safety Commission and the National Injury Information Clearinghouse from 1998 reported that injuries requiring hospital emergency room visits from baseball included estimated totals of more than 4,200 upper trunk injuries, 4,600 lower trunk injuries, 1,300 neck injuries, 8,200 mouth injuries, 8,200 shoulder injuries, 17,900 head injuries, 42,000 face injuries, and 2,600 eye injuries; similarly, from the same report for 2000, there were reported more than a total of 182,000 injuries, including 5,100 upper trunk injuries, 5,200 lower trunk injuries, 8,800 shoulder injuries, 18,100 head injuries, 39,000 face injuries, and 3,400 eye injuries. Furthermore, in 2000, basketball injuries totaled more than 600,000; boxing, more than 13,000; football, nearly 400,000, hockey, ice hockey, street hockey and field hockey, more than 69,400; soccer, more than 185,000; lacrosse, more than 7,400; sledding, more than 38,000; and gas, air or spring-operated guns, as in paint ball, more than 17,000. Overall, sporting-related injuries that required hospital emergency room visits were estimated to be more than 3.4 million in 2000, according to these statistics. These figures do not include visits to private physicians or other medical care providers.

[0008] By way of example, applicant's son, James Patrick LaShoto, was struck by a foul ball in the on-deck circle during a little league baseball game for 8-10 year olds in Waltham, Mass. in May 2001, which resulted in a 5-inch diameter bruise on his stomach for more than one month. He had little time, if any, to react in order to move out of the way or protect himself from being hit. Also, he was playing second base in baseball in June 2001 when he was struck by a baseball in the face, in particular the eye region. Fortunately, he was wearing virtually shatterproof polycarbonate sunglasses for protection, which likely prevented a permanent injury or blindness in his right eye. Thus, by way of real-life case-in-point, the use of protective devices for sports participants, especially for children, is valuable.

[0009] The shin, calf and Achilles regions of hockey, football, soccer players and other contact field sports are exposed. Frequently during play, players receive accidental foot strikes to the calf region from other players. If the striking player is wearing cleated shoes, roller skates, ice skates, or similar foot apparel, the force of the strike may be focused onto a small area, as opposed to flat-soled shoes, where the force of the strike is spread over a larger area. Alternatively, the player may be struck with the edge of the shoe. Such strikes can cause a variety of problems, including soft tissue, bone, ligament, and tendon injuries.

[0010] Soft tissue injuries are likely to result in hematomas, which are painful and can cause a player to be sidelined. Moreover, blood clots formed in the hematoma can break off and travel to other parts of the body, eventually coming to the lungs and causing pulmonary infarcts. In this manner, the clot blocks the flow of blood in that area.

[0011] Soft tissue injuries may also progress to ossification, resulting in impaired function. Ossification of muscle tissue, known as posttraumatic myositis ossificans, is a condition characterized by heterotopic bone formation in the soft tissues following trauma. The process occurs most often in muscle, but may also occur in ligaments, tendons, fascia, and joint capsules.

[0012] Bone trauma can result in a variety of sequelae—osteomyelitis, reflex sympathetic dystrophy syndrome, osteonecrosis, osteoarthritis, intraosseous fracture (bone bruise), fracture and cancer.

[0013] Fractures are breaks in the bone or cartilage. Fracture complications can be immediate, intermediate, and delayed. Immediate complications include arterial injury, compartment syndrome, gas gangrene, fat embolism syndrome, and thromboembolism. Intermediate complications include osteomyelitis, reflex sympathetic dystrophy syndrome, posttraumatic osteolysis, myositis ossificans, and synostosis. Delayed complications include osteonecrosis, degenerative joint disease, osteoporosis, aneurysmal bone cyst, nonunion, and malunion.

[0014] Osteonecrosis, also known as avascular necrosis is a focal bone infarction, which may be secondary to trauma. The most common sites of posttraumatic avascular necrosis are the femoral and humeral heads and the body of the talus.

[0015] Degenerative joint disease, also known as osteoarthritis, is an arthropathy with altered hyaline cartilage and characterized by loss of articular cartilage and hypertrophy of bone, producing osteophytes. It is a form of arthritis that results in the destruction of the articular cartilage that line the joints and often is cause by trauma.

[0016] Aneurysmal bone cyst, a type of malignant cancer, has been documented to follow a traumatic event. It is believed to occur via the conversion of a sub-periosteal hematoma into an expansile tumor.

[0017] Several types of joint injuries due to trauma are observed. Joint subluxation is the abnormal movement of one of the bones that comprise a joint. This is not a true dislocation, but a partial dislocation. Diastasis is the traumatic separation of bones at a suture line or at a slightly movable joint, a syndesmosis. Common locations for this to occur are the pubic symphysis and the distal tibiofibular syndesmosis. The chondral and osteochondral fractures are fractures through a joint surface, and are observed at the convex surfaces of the femoral condyles, talar dome, and capitulum. Epiphyseal fractures are fracture through a growth plate.

[0018] Tendon and ligament trauma can also result from impact injuries. Common injuries of these types include lateral collateral ligament injury, achilles tendonitis and rupture, and tibialis posterior tendon injuries. Injuries can occur from a direct strike to the tendon or ligament, or can result from a blow to the tendon or muscle that causes a reflex contraction that ruptures or strains the tendon.

[0019] Regional osteoporosis as a sequel to trauma can be manifested as reflex sympathetic dystrophy syndrome and disuse and immobilization osteoporosis, e.g. from being in a cast or wheelchair.

[0020] Impact-resistant protective devices that could be used to protect the calf region are cumbersome, heavy, or hot and may restrict movement, which may discourage sports players or participants from wearing adequate protection to prevent injury in the event of foot strikes to the calf region. Most likely, the added restrictions these shields would confer are a reason for the lack of use of calf guards by contact field sports players. Thus, there remains a need for a protective device that permits freedom of movement and breathability during athletic activity while offering protection from injurious foot strikes to the shin, calf and Achilles regions.

SUMMARY OF THE INVENTION

[0021] The present invention is directed to a body protective device for providing protection to the shin, calf and Achilles regions from impact-based injuries, especially relating to sports activities.

[0022] The present invention is directed to a protective device having a substantially flexible outer garment enclosing soft and rigid composite elements or shields that are premolded or custom-fit to conform to the shape of the user's shin, calf and Achilles regions.

[0023] One aspect of the present invention is to provide a protective device for the shin, calf and Achilles regions for players of sports including a fabric-based covering encasing composite elements and that is premolded or custom-fit to the user, is lightweight, and that presents a low profile so as not to inhibit freedom of movement of the user during athletic activities.

[0024] Another aspect of the present invention is to provide a protective device for the shin, calf and Achilles regions for players of sports including a fabric-based covering that includes selectively removable composite elements and that is premolded or custom-fit to the user, is lightweight, and that presents a low profile so as not to inhibit freedom of movement of the user during athletic activities.

[0025] Basically, one advantage of the invention is that by having a pad in close intimate contact with the shin, calf and Achilles regions, in particular, from the compression of the garment, wherein the better fit provides improved impact dispersion of blunt trauma forces. This occurs because more of the protective pad is in contact with the body reducing point loading and allowing superior impact dispersion. When compared to traditional pad systems that are not adequately contoured to the body shape, the calf compression garment provides a superior “fit” of the pads that equals superior protection.

[0026] These and other aspects of the present invention will become apparent to those skilled in the art after a reading of the following description of the preferred embodiment when considered with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0027]FIG. 1 is a side view of a calf and Achilles regions protective device constructed according to the present invention.

[0028]FIG. 2 is a side view of an alternate embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0029] In the following description, like reference characters designate like or corresponding parts throughout the several views. Also in the following description, it is to be understood that such terms as “forward,” “rearward,” “front,” “back,” “right,” “left,” “upwardly,” “downwardly,” and the like are words of convenience and are not to be construed as limiting terms.

[0030] Referring now to the drawings in general, the illustrations are for the purpose of describing a preferred embodiment of the invention and are not intended to limit the invention thereto. The present invention provides for a protective device that is formed by a substantially flexible outer garment and protective elements, in particular soft elements and rigid elements, that are provided within the outer garment for protecting the calf from injury related to impact during sports or athletic activities. The elements combine to form an overall composite shield, which is collectively provided by the either rigid elements or soft elements, depending upon the level of impact resistant and/or energy absorption desired. The elements are insertable into the garment either during manufacturing, or by the user prior to use of the protective device. In a preferred embodiment, the elements are selectively removable, and may be inserted into pockets within the garment or attached by fasteners, e.g., hook and loop type fasteners, snaps, buttons, hooks and eyes, and the like. In another embodiment, the elements are fixed, in particular to ensure that the best and most complete protection possible from all elements is provided and cannot be tampered with.

[0031] The outer garment may be variably sized to cover the calf and more or less of the region of the body proximal to the calf of the user, including the back of the knee and Achilles tendon.

[0032] One embodiment of the present invention, shown in FIG. 1, includes a protective device for the shin, calf and Achilles regions, generally referenced 10, including a fabric outer garment 12 and protective elements for the calf 14, shin 16, and Achilles tendon 18, in particular a composite element with soft elements and rigid elements, that is selectively provided in a predetermined location within the outer garment and housed within a pocket 15 in the garment for protecting the calf area and proximal body parts from injury related to impact during sports or athletic activities. Another embodiment is shown in FIG. 2, wherein the protective elements extend over a larger area of the shin, calf and Achilles regions than in FIG. 1 and further includes protection in the foot instep region 24. The protection can also be extended to the top and sides of the toes. Connective webbing 20 is provided between the pads to provide for increased freedom of movement and breathability, while still providing protection over the critical shin, calf and Achilles regions.

[0033] The semi-rigid and rigid elements are composite elements formed of fabric elements, in particular woven, knitted, or braided fabrics, either in single or multiple layers are used; preferably, 3D engineered fiber preforms or fabrics are used, which are formed by a 3D fabric-forming method selected from the group consisting of 3D weaving, 3D braiding, 3D circular weaving, and multiaxial weaving. Alternatively, plastic, injection-molded pieces are used for the semi-rigid and rigid elements in another embodiment according to the present invention. In particular, true 3D weaving involving three orthogonal, non-interlacing yarn systems are preferred; such true 3D woven constructions are formed by the methods set forth in U.S. Pat. No. 5,085,252 issued Feb. 4, 1992 to Mohamed, et al. for METHOD OF FORMING VARIABLE CROSS-SECTIONAL SHAPED THREE-DIMENSIONAL FABRICS which is incorporated herein by reference in its entirety. Also, U.S. Pat. No. 5,465,760 issued Nov. 14, 1995 to Mohamed, et al. for MULTILAYER THREE-DIMENSIONAL FABRIC AND METHOD FOR PRODUCING is also incorporated herein by reference in its entirety. Elements to protect different organs or regions may be formed from different fabric-forming methods, such that the overall protective device may include a variety of element types or homogeneous elements. These composite elements are preferably formed of pre-shaped components including shells or sheaths of 3D engineered materials that are infused with resin, e.g., vinylester, for providing additional stiffness, strength, and/or impact-resistance.

[0034] The outer garment may be fabricated using a close-fitting material, preferably one with at least some memory so that the user's general body shape is maintained during use and is retained during subsequent uses. Also, breathable material is preferred so that the user is not uncomfortable due to extra heat induced by the garment during wear and activity. It is preferred that the material be cleanable, more preferably washable, since use during athletic activity would likely soil the garment. Additionally, a protective, soil-resistant coating may be applied. The outer garment preferably includes materials having breathability, such as COOLMAX fabric, which is commercially available by DuPont. Another commercially available breathable polypropylene fabric that is tight fitting is commercially available by Under Armor at www.underarmor.com. Other similar or equivalent materials are considered to be applicable and within the scope of the present invention.

[0035] In one embodiment according to the present invention, the garment is made of a knitted spacer material for providing a predetermined bulk while maintaining a lightweight, stretchable fabric. Additional stretch may be provided, as needed, by the introduction of SPANDEX material into the spacer material.

[0036] The elements may be pre-shaped or pre-molded. The elements include both premolded foam padded elements and rigid, composite elements. The premolded foam padded elements offer soft protection for the shin, calf and Achilles regions in low-impact sport activities. Whereas during high-impact activities, rigid, composite elements that are molded into the garment can be used in order to offer close and comfortable fitting of the protective device.

[0037] Also, these composite elements may be custom-fitted and molded into the garment; alternatively, these may be removable, e.g., for washing or cleaning the garment. Additionally, these elements may be removable in order to provide the user with selective protection, depending upon the level of protection and risk associated with the particular sports activity. A custom-fitted version is considered to be the best mode of the invention, in order to provide the optimal level of protection and freedom of movement or overall performance of the protective device according to the present invention. In one embodiment, where a custom-fitted garment includes 3D engineered fiber structures that are preformed to a near net shape element or formed, cut, and approximately shaped to a predetermined sized element, depending upon the size of the shin, calf and Achilles regions to be protected, the element is treated with a resin that is either moisture- or temperature-curable, such that exposure to either moisture or higher than body temperature, respectively, provides for activation and setting of the resin in order to form a rigid composite element. In an alternative embodiment, the outer garment can be purchased to fit an approximate shin, calf and Achilles regions size and shape, e.g., extra-small, small, medium, large, extra-large, etc. and may be provided for either male or female body types or for unisex shaping, depending upon height and size of the user. The padded elements and rigid composite elements are provided separately such that they may be selectively inserted and removable from the outer garment. In a preferred embodiment, pockets are provided for maintaining the elements in an approximate position to protect the body parts and organs; in another embodiment, attachment means or fasteners such as hook and loop type fasteners, e.g., VELCRO, are provided to ensure releasable attachment with the garment during use.

[0038] The preforms used for the composite elements are manufactured from engineered fibers, in particular synthetic fibers, and including but not limited to KEVLAR, fiberglass, carbon, nylon, and combinations thereof. The padded elements are preferably manufactured from a resilient material, such as foams, including molded dual density foam, polyurethane, neoprene, and EVA foams. Preferably, the foam is selected from EVA or polyurethane foams, or foam alternatives, or other comfort liner materials.

[0039] Foam alternatives may include materials such as SKYDEX padding, which is commercially provided by Skydex; as set forth in the website www.skydex.com, and which provides for improved durability for washing and cleaning when compared with many foams, as well as improved performance and impact resistance, and it maintains its energy absorbing and/or energy dispersing qualities, while not absorbing moisture. Perforations in such foams are desirable in order to ensure some breathability of the overall protective wear when using soft padded elements. Another breathable foam or foam alternative material that may be used with the present invention is SPACENET, which is commercially provided by Spacenet, as listed in the website www.spacenetmaterials.com.

[0040] The overall protective device, including the outer garment and the protective elements, both soft padded and rigid composite elements, are preferably custom-fitted to the user, are lightweight, and present a low profile so as not to inhibit freedom of movement of the user during athletic activities. As set forth hereinabove, the elements may be initially flexible with later hardening after conforming substantially to the user's body shape and size, or the elements may be partially flexible and partially rigid, thereby forming an articulated protective device when connected with the outer garment. These elements may be joined by the outer garment itself, or they may alternatively or additionally be joined by webbing or other connective means, including jointing, stretch webbing, hook and loop type fasteners such as VELCRO fasteners, or they may be overlapped or hinged, preferably by synthetic or plastic connectors. The joined or jointed elements act as discrete protective components and can move relative to each other, thereby providing freedom of movement required for sports activities while providing protection for the shin, calf and Achilles regions covered with the device and its elements. Furthermore, the elements may be disc-shaped components or substantially body part-shaped components in order to provide the optimal coverage and moveability for the user.

[0041] Overall, one advantage of the invention is that by having a pad in close intimate contact with the body, in particular, from the compression of the garment, wherein the better fit provides improved impact dispersion of blunt trauma forces. This occurs because more of the protective pad is in contact with the body reducing point loading and allowing impact dispersion. When compared to traditional pad systems that simply “hang” from the body, the compression garment provides a superior “fit” of the pads equals superior protection.

[0042] A significant advantage is provided by the use of three-dimensional (3D) materials such as those supplied commercially by 3TEX, Inc. of Cary, N.C., in that the materials provide a decrease of about 20% in the force transferred to the body, with approximately a 20% lighter weight compared to traditional materials, e.g., ABS plastic listed in Table 1 below. Test results as measured by an independent drop test device, which simulates impacts and records energy dispersing properties of the materials tested, show the following data for the present invention when compared with the prior art. The following test results of Table 1 illustrate the advantages of the use of the 3D materials when compared with traditional materials used in other protective device applications: TABLE 1 ABS plastic v. 3TEX Composite Impact Research Study Anvil Carbon/ FG/Poly E-Glass Material ABS Keviar Red/Blue Red Hybrid 28 Hybrid 29 Location Impact Date Aug. 7, 2001 Aug. 7, 2001 Aug. 7, 2001 Aug. 7, 2001 Sept. 18, 2001 Sept. 18, 2001 Flat 0 Front 256.4 242.8 251.9 249.6 235.0 247.3 45 Front Right 90 Right 135 Rear Right 180 Rear 234.6 255.5 238.2 240.0 222.7 217.7 225 Rear Left 270 Left 315 Front Left Flat 0 Front 242.8 238.7 45 Front Right 90 Right 135 Rear Right 180 Rear 213.2 206.8 225 Rear Left Hemi 0 Front 45 Front Right 90 Right 161.2 160.8 168.5 157.6 143.5 150.3 135 Rear Right 180 Rear 225 Rear Left 270 Left 315 Front Left Hemi 0 Front 45 Front Right 90 Right 146.2 144.4 135 Rear Right 180 Rear 225 Rear Left 270 Left 315 Front Left Edge 0 Front 45 Front Right 90 Right 135 Rear Right 180 Rear 225 Rear Left 270 Left 139.4 130.3 136.6 134.4 136.6 125.7 315 Front Left Edge 0 Front 45 Front Right 90 Right 135 Rear Right 180 Rear 225 Rear Left 270 Left 130.3 114.3 315 Front Left

[0043] Certain modifications and improvements will occur to those skilled in the art upon a reading of the foregoing description and research results. By way of example, substitute three-dimensional (3D) materials, including other resin-infused materials may be used; other energy dispersing foams in combination with the 3D resin infused materials may be used; and other breathable and/or tight fitting garments may be used without departing from the scope of the present invention. Furthermore, different artwork, such as the name of a sponsor or a team may be silk-screened and then heat transferred onto the device for marketing and advertising attractiveness.

[0044] All modifications and improvements have been deleted herein for the sake of conciseness and readability but are properly within the scope of the following claims. 

We claim:
 1. A protective device for providing protection from injuries to the shin, calf and Achilles regions of a user comprising: a substantially flexible outer garment further including protective elements that are provided in predetermined locations within the outer garment to provide impact-resistance from objects, thereby providing protection of the shin, calf and Achilles regions and other body parts from injuries related to impact during sports or athletic activities.
 2. The device according to claim 1, wherein the protective elements are soft elements and rigid elements.
 3. The device according to claim 1, wherein the elements are selectively removable.
 4. The device according to claim 1, wherein the elements are fixedly attached to the outer garment.
 5. The device according to claim 1, wherein the elements are secured in pockets in the outer garment.
 6. The device according to claim 2, wherein the rigid elements are formed of three-dimensional engineered materials.
 7. The device according to claim 6, wherein the three-dimensional engineered materials are 3D woven fabrics.
 8. The device according to claim 7, wherein the 3D woven fabrics are further treated with a resinous substance to create rigid composite elements.
 10. The device according to claim 2, wherein the soft elements are formed of foam-like material.
 11. The device according to claim 10, wherein the foam-like material is a foam, selected from the group consisting of molded dual density foam, polyurethane, neoprene, and EVA foams.
 12. The device according to claim 1, wherein the elements are preformed to a similar shape as the body parts for which they provide protection.
 13. The device according to claim 1, wherein the elements are substantially matching to the body parts for which they provide protection.
 14. The device according to claim 1, wherein the elements are custom-fit to the individual who will be wearing the device.
 15. The device according to claim 1, wherein the elements are custom-molded to the user's anatomy.
 16. The device according to claim 1, wherein the substantially flexible outer garment is attachable to/covering the shin, calf and Achilles regions of the user.
 17. The device according to claim 16, wherein the outer garment is attachable to equipment proximal to the shin, calf and Achilles regions.
 18. The device according to claim above, wherein the device is attachable to the shin guard.
 19. The device according to claim 1, further including at least one protective element in the foot instep region for providing protection to the instep region.
 20. The device according to claim 1, further including at least one protective element in the toe region for providing protection to the toes. 